FICCI : Industry's Voice for Policy Change - White Paper on ...ficci.in/spdocument/20684/PVC-Report.pdf10.3 kg per capita in China (ref to figure 3). The forecasts for the PVC industry

Enabling 'Make in India' by Strengthening Indian Manufacturing& Reducing Country's Import Dependency

Knowledge and Strategic Partner

White Paper on

Enhancing Competitiveness ofIndian PVC & Caustic Soda Industries

Knowledge and Strategic Partner

Enabling 'Make in India' by Strengthening Indian Manufacturing& Reducing Country's Import Dependency

White Paper on

Enhancing Competitiveness ofIndian PVC & Caustic Soda Industries

Message

PVC and Caustic Soda industry (both of which are inter-linked) are two basic segments of

Indian industry which facilitate a chain of down stream industry such as agriculture,

infrastructure, housing and sanitation etc. These sectors are stagnating in the country, with

increasing dependence on imports. The last greenfield investment for a PVC plant in India was

conceived in the year 2002-03 and operations started in 2007.This is not a sustainable

scenario with a long term perspective for a large economy like India.

It is gratifying that an initiative has been undertaken for bringing out a White Paper which

provides a holistic approach to issues and challenges being faced by the Chloro Vinyl industry

as also the way forward. I am sure, it will be found useful by all stake-holders.

Mr. Vinay MathurDeputy Secretary General

The Chloro Vinyl industry is an important component of national economy comprising the Poly

Vinyl Chloride (PVC) and the chlor-alkali industries. These are basic industries which are

essential to the growth of Indian economy. They provide products with applications in a

variety of sectors. Indian Poly Vinyl industry is presently not doing well. Import of PVC, which

was less than 5% of the country's demand ten years ago, is now at almost 50% and is growing.

The PVC industry also has a linkage to the Caustic soda industry. Majority of Chlorine

produced goes into PVC manufacture, and if there is no PVC capacity addition, there can be no

Caustic Soda capacity addition. As a result imports are increasing.

That is not a healthy sign and has long term implications for national economy. To bring out

the challenges and issues of the sector, a White Paper on enhancing competitiveness of Indian

Choloro Vinyl industry has been prepared. It is evident that the situation is grave and needs

attention from all stake-holders.

Mr. Prabh DasChairman-FICCI National Petrochemicals CommitteeManaging Director & CEOHPCL-Mittal Energy Limited

Preface 01

1. Why focus on PVC and Caustic Industries? 02

2. PVC 04

3. Need for strengthening domestic PVC production 11

4. What ails PVC and Caustic capacity addition? 18

5. Recommendations for augmenting PVC & Caustic Soda Capacities 22

6. Conclusions 23

7. Abbreviations 24

8. About Tata Strategic 25

9. Tata Strategic Contacts 26

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04

Global scenario . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04

Indian Scenario . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06

Future Potential in India . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rising supply – demand gap in PVC will make imports unsustainable. . . . . . . . . . . . . . . . . . 11

Caustic Soda domestic capacity additions being hindered by lack of PVC capacity growth . . . . 15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Free Trade Agreements - Relevance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Table of Content

Knowledge and Strategic PartnerWhite Paper on Enhancing Competitiveness ofIndian PVC & Caustic Soda Industries

01

Poly Vinyl Chloride (PVC) industry is important for national economy. Investments are not happening

despite the rapidly growing Indian PVC market. The last greenfield investment for a PVC plant in India was

conceived in the year 2002-03, when duty differential was a little over 15%. However, while demand has

grown by almost 1.6 million tons no new capacity addition has even been envisaged. Indian import duties

on PVC are lower than those in the developed world and in the ASEAN Region. Imports of PVC, which were

less than 5% of the country's demand ten years ago, are now at almost 50% and growing rapidly every

year and are expected to reach to $3 billion in a few years. Appropriate fiscal measures can propel

investments in the PVC sector. It also has a very serious long term deleterious effect on the Indian

Caustic Soda industry. The majority of Chlorine produced goes into PVC manufacture, and if there is no

PVC capacity addition, there can be no Caustic Soda capacity addition, and the country will become

reliant on the import of yet another basic growing product, Caustic Soda.

The issue has been well debated in the FICCI National Petrochemical Committee, which decided that a

White Paper on the subject may be brought out. The ultimate objective of same is Enabling 'Make in

India' by Strengthening Indian Manufacturing & Reducing Country's Import Dependency. The result is

this Paper which, it is hoped places these important segments of Indian industry in proper perspective

thus facilitating appropriate actions by stake holders, including the Policy makers.

Preface


02

The PVC industry in India is valued at over Rs. 20,000 crores with five major producers and over 6,000

processors, employing tens of thousands of people, making consumer and industrial products. In spite of

strong economic growth, India still has a long way to go to realize its infrastructural needs - nearly USD

650 billion will be required for urban infrastructure in the next twenty years. Also, the construction

sector contributes to 10% of the GDP. This provides great opportunity for investment and hence for PVC

products that are used in these sectors.

Caustic soda is a basic building block finding application in a variety of industries and chlorine is an

essential element, finding application in products of everyday use, including in life saving medication.

The Indian caustic & chlorine industry is estimated at over Rs.7, 000 crores annually, provides

employment to about 1.5 lakh people (direct & indirect) and contributes over Rs.100 crores to the

exchequer by way of duties and taxes.

Why focus on PVC and Caustic Industries? 01

Source: Market Research

Sodium Chloride (NaCI)

Caustic Soda (NaOH) Chlorine (CI )2 Ethylene (C H )2 2

Polyvinlyl Chloride (PVC)

Vinyl Chloride Monomer (VCM)

Ethylene Dichloride (EDC)

Figure 1: PVC value chain

PVC is a product which is derived at the end of a value chain (ref fig 1) that begins with common salt

(NaCl). Caustic and chlorine are produced from NaCl. Chlorine and ethylene gives EDC which is used to

produce VCM. PVC is derived from VCM. There is an enormous gap between supply and demand in both PVC

and caustic industries, which would only increase at a rapid pace as we go forward. Capacity creation

doesn't seem to be taking place, even to the extent of part of the demand growth. In the case of caustic

soda, the inadequate means to sink incremental chlorine has been a bother for the industry for long. The

vinyl industry is the single largest consumer of chlorine globally. Unless this sector expands in India,

there is no real chance for substantial capacity addition in caustic. Even the existing capacities are

threatened by the increased arrival of imports that has depressed margins for domestic players over the

course of the last few years, thus resulting in inadequate utilization/augmentation of domestic

capacities.


03


04

PVC 02

Introduction

Global scenario

Fundamentally, PVC is a synthetic resin made from the polymerization of vinyl chloride. It is the third

largest plastic in production and consumption. Technology has gradually improved over time with

improvements in safety, product quality, production volume, environmental issues and cost. A key

feature of PVC is that it can be combined with additives and fabricated into a wide variety of forms. These

include pipes and fittings, profiles and tubes, windows and doors, sidings, wires and cables, film and

sheets, toys and other moulded products and floorings. This quality, together with features such as

durability, self-extinguishing property, resistance to most chemicals and oil, mechanical strength and

ease of processing, means that PVC is a competitive and attractive option for many end uses in

construction and infrastructure, agriculture, electrical products and healthcare. Further, only 43 % of

PVC's content comes from oil. The balance 57% comes from salt, meaning that PVC is less dependent on

fossil fuels compared to other materials. This feature, coupled with the fact that PVC products can last up

to 100 years, can be recycled and can provide products with good quality to price ratio, greatly reduces

life cycle costs of PVC.

Globally, the growth of the industry over the last 100 years has been spectacular. Production capacity has

grown from a few thousand tons in the 1930s to over 50 million tons today. The global capacity break-up

is given below.

Growth in demand will be concentrated in developing countries in Asia, Africa, Latin America and the

BRICS. The per capita consumption in India of 2kg is low compared to 11.8kg per capita in the US and

10.3 kg per capita in China (ref to figure 3). The forecasts for the PVC industry are bright. The global

market, currently at US$ 56 billion, is expected to reach revenue of US$65 billion in 2019, with average

annual demand expected to increase at 3.9%.

NE Asia, 55%

SE Asia, 4%

North America, 16%

South America, 3%

Middle East, 2% Indian Subcontinent, 3%

Africa, 1%Central Europe, 4%

Western Europe, 12%

Source: Industry Reports

Figure 2 - Global PVC capacity break-up (%)

Figure 3 - Per capita consumption of Suspension PVC

2

5.6

7.6

8.8

10.3

12.7

0

2

4

6

8

10

12

14

India Brazil Malaysia Thailand China USA

Qua

nti

ty(k

g pe

r pe

rson

)



05

The global consumption of PVC in 2014 was estimated at 40 million tons. The region wise break-up is

given below.

Figure 4 - Global PVC demand break-up

Africa, 3%

Indian Subcontinent, 7%

Middle East, 6%

Central Europe, 2%

Western Europe, 10%

South America, 5%

North America, 13%

SE Asia, 5%

NE Asia, 46%


Indian Scenario

India has been producing PVC for over 50 years now, with the first plant of 6ktpa capacity set up by Calico

Mills Ltd., in Mumbai in 1961. After this, India never looked back till about the mid-2000s (ref to figure

5), with capacity keeping pace with demand.

Figure 5 : Historic PVC Capacity Additions in India

Historic Capacity Addition (ktpa) Chemplast, Cuddalore

170 IPCL, Gandhar

150Finolex, Ratnagiri

130Reliance Hazira

160

IPCL Vadodara

55

DCW Tuticorin

30

NOCIL Thane 21.5

Chemplast, Mettur

6

DCM Shriram,

Kota 7

Calico Mills,

Mumbai 6

1961 1964 1967 1968 1971 1984 1990 1992 1998 2009

Note: 1) Calico Mills and NOCIL facilities are shutdown and are not operational. 2) Any further capacity addition in these plants are not included since their commissioning dates.


06

The figure below illustrates how, after the drop in duty levels in mid 2000s, capacity addition completely

lagged demand growth, resulting in the zooming import numbers.

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

50%

0

200

400

600

800

1000

1200

1400

1600

1800

2000

FY94 FY95FY96FY97FY98FY99FY00FY01FY02FY03FY04FY05FY06FY07FY08FY09FY10FY11 FY12FY13FY14FY150%

5%

10%

15%

20%

25%

30%

35%

40%

45%

50%

0

200

400

600

800

1000

1200

1400

1600

1800

2000

Note: In case where importy duty has been changed within the the FY, the customs duty that has been levied for majority of the months with in that FY has been taken

Domestic production Imports Imports as a % of consumptionImports

Source: Industry research, EXIM data, CPMA

Qua

nti

ty in

KT

Impo

rt D

uty

/ Pe

roen

tage

of

Impo

rts

to c

onsu

mp

tion

Figure 6 : PVC production and imports in India

The PVC industry in India has historically been driven by agriculture till 2000. Thereafter, the main driver

for PVC consumption has been infrastructure growth. For instance, Pipes & Fittings, that constituted only

14% of the total consumption in 1975, has grown to over 70% now (ref to figure 7).

Figure 7 - PVC demand in India - History

0

500

1,000

1,500

2,000

2,500

3,000

1972 1975 1980 1985 1991 1995 2000 2005 2010 2014 2015

Qua

nti

ty (

kt)


07

Currently, in India, approximately 73% of the PVC is consumed by the Pipes & Fittings industries with the

other sectors comprising only 27%. Globally, Pipes & Fittings account for only 43% of the PVC

consumption, showing that PVC applications in India other than Pipes & Fittings are still in the early

stages and are primed for growth. This, along with the relatively low per capita PVC consumption in India,

shows that future prospects for the Indian PVC processing industry are bright.

Figure 8 - Application break-up of PVC – India

Flooring 8%

Others6%

Wires & Cables 5%

Films & Sheets 5%

Profiles 3% Pipes & Fittings73%

Figure 9 - Application break-up of PVC - Global

Others 10%

Floorings 3%

Wires & Cables 8%

Films & Sheets 17%

Profiles19%

Pipes & Fittings43%

The total demand for PVC in the country in 2014-15 was at 2,564kt. The demand grew by 6% compared to

2013–14 (ref to figure 10).


08

The figure below illustrates how, after the drop in duty levels in mid 2000s, capacity addition completely

lagged demand growth, resulting in the zooming import numbers.

-10%

-5%

0%

5%

10%

15%

20%

25%

30%

0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

Figure 10 - PVC consumption in India (2001-2015)

2001-02

2002-03

2003-04

2004-05

2005-06

2006-07

2007-08

2008-09

2009-10

2010-11

2011-12

2012-13

2013-14

2014-15

Qua

nti

ty (

kt)

Gro

wth

rat

e (%

)

Source: CPMA Industry research

For the period between 2002 and 2015, the total demand for PVC in the country grew at a CAGR of 8.7%.

During the same period domestic production capacity grew at a CAGR of 4.6 % whereas imports grew at a

CAGR of 32.5%.

The domestic manufacturers and their respective current capacities are given below:

Figure 11 : Domestic manufacturers and capacities (kT)

750

365

26090 70 1535

Reliance Chemplast Finolex DCW DCMShriram

Total



09

Future Potential in India:

Indian PVC demand in the future will be driven by the following sectors

1) Agriculture: The government has emphasized on bringing in increased land under irrigation.

2) Infrastructure: The Government is focusing on rural water and sanitation infrastructure which

will be a huge consumer of PVC pipes. The development of 'smart cities' will be a further boost to

PVC consumption in India due to the huge requirement of urban infrastructure in these cities.

3) Housing: The demand for housing from the middle income group in India is expected to increase

in the coming years and the Government is taking active steps to bridge the gap in supply. It is

estimated that every year, 2 million housing units are built in urban areas while 4.5 million units

are built in rural areas. One typical urban unit will require about 200 kg of PVC in major

applications like pipes, doors & windows, conduits, wires & cables, etc. while one rural unit

requires approximately 75 kg of PVC. Thus, the potential for PVC in the building and construction

sector alone is over 700 ktpa (without taking smart city development into account). Moreover,

introduction of green building concepts is picking up. PVC, being recyclable, less energy

intensive and having longer life will be in demand in these segments. Furthermore, development

of smart cities initiative from government will further drive the urban housing demand.

4) Other sectors: PVC has packaging as well as other applications in the FMCG, pharmaceutical &

retail segments. These sectors are expected to grow in the coming years as the customer base

comprising India's young population increases.

Further, there are a number of applications in India, which are still nascent or currently

unexploited like, wall cladding, technologically-advanced pipes for sewerage application, liners

for landfill applications, decking, furniture applications, waterproofing membranes and food

grain storage.

These products are well established abroad and with ever-increasing urbanization, changing

lifestyles, new technologies in construction and other factors, investments in these sectors are

expected in the future. This bodes well for the PVC industry. Taking into account the above demand

drivers and the CAGR in demand of around 9% from 2002-2015, it is estimated that annual demand

growth for PVC will be at least 13% in the next five years. Demand is expected to cross 5 million tons

in 2020.

2,5632,896

3,2723,698

4,1784,722

5,335

0

1,000

2,000

3,000

4,000

5,000

6,000

2014-15 2015-16* 2016-17* 2017-18* 2018-19* 2019-20* 2020-21*

Qua

nti

ty (

kt)

Source: CPMA reports

Figure 12 : Demand forecasting for PVC


10

03

Rising supply – demand gap in PVC will make imports unsustainable

India's supply – demand imbalance in PVC means that the deficit in demand is met by imports. As seen

earlier, for the period between 2002 and 2015, the total demand for PVC in the country grew at a CAGR

of 8.7%. During the same period domestic production grew at a CAGR of 3.7 % whereas imports grew at

a CAGR of 32.5%.


11

Figure 13 : Supply-Demand for PVC (kT)

0%

10%

20%

30%

40%

50%

60%

0

500

1,000

1,500

2,000

2,500

3,000

FY02 FY03 FY04 FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15

PVC Production (kt) PVC Import (kT) Import as a % of consumption

Source: CPMA, Exim Data, Industry Research

Need for strengthening domestic PVC production

Looking at the imports statistics for the period April 2014 – September 2015, it is seen that the top five

countries that export to India, namely, Taiwan, Korea (South), China, Japan and Iran, account for 87% of

the total imports into India, with just Taiwan & Korea (South) alone contributing to over 50%.

Figure 14 : Annual growth rate of industry (%)

Figure 15 - Region wise break-up of PVC imports (April 2014- September 2015)

Taiwan 28%

Others 5%U S A 1%

Germany 1%

Vietnam 1%

Norway 2%

Thailand 3%

Iran 5%

Japan 8%

China 21%Korea 25%

Source: Exim Data

As mentioned earlier, demand growth is expected to increase at 13% in the coming years. With any grass

root plant taking almost 4-5 years to fructify and with no announcement as on date on creation of fresh

capacity in the country, domestic production capacity, and therefore production, is expected to increase

marginally or remain at around the same levels during this period. As a result, by 2020, India would need

approximately 3,700kt of imports i.e. an additional 2,300kt from the present level to meet its PVC

demand.


12

-20%

20%

60%

100%

140%

180%

220%

FY03 FY04 FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15

Production growth (%) Import growth (%) Demand growth (%)


0%

10%

20%

30%

40%

50%

60%

70%

80%

0

1,000

2,000

3,000

4,000

5,000

6,000

2014-15 2015-16* 2016-17* 2017-18* 2018-19* 2019-20* 2020-21*

PVC Production (KT) PVC Import (KT) Import as a % of consumption

This level of imports will be highly unsustainable. For instance, the top 5 importing countries (excluding

India) & their quantum of imports expected in FY16, is given here:

Figure 16 - PVC import projection in India

Figure 17 : Top Five Importing Countries (kT)


Source: Exim reports

As can be seen, even today, no other country imports over a million metric tons per year. This is a clear

reflection of the difficulty level in trying to import 3-4 million tons per year. Such high levels of imports

will also have a deleterious effect and the resultant net outflow of foreign exchange could be of the order

of US $5 billion. Another factor that goes to show that this level of import is almost impossible is the

estimated global trade in PVC resin by the year 2020 which is at around 10 million tons. It will again be

not prudent for India to expect that almost 37% of this will be an inflow into the country.

If we look at countries with sizable consumption volumes, it can be seen that these are the ones with

adequate – in fact surplus – resin capacity, except for India. The following table will illustrate this fact.


13

930

700500

450450 3030

Turkey China Russia Canada Brazil Total

Country Capacity (kt) Domestic Demand (kt) Surplus Capacity (kt)

Taiwan 1,930 700 1,230

Korea 1,470 700 770

Japan 2,090 1,450 640

China 24,300 14,800 9,500

Iran 730 350 380

USA 7,950 4,600 3,350

Source: Industry reports

Figure 18 - Countries with surplus capacity

A hypothetical analysis of the projected supply – demand balances in the top five exporting countries in

2020 would also show that, even if they were to stop exporting to all other countries and divert their

entire surplus to India, it still would not be adequate to meet our demand. The following assumptions are

taken into account.

I. Setting up petrochemical plants requires high lead times. Capacity expansion has stagnated in

both Taiwan and Korea. Taiwan is expected to gradually increase production by way of better

capacity utilization. Growth of Chinese capacity addition has decreased drastically and capacity

is expected to be at 25,200 kt in 2020. Production is expected to increase by way of capacity

utilization in China, Japan and Iran

II. Demand is assumed to be same in Taiwan, Korea, Japan & Iran while it is assumed to grow at a

CAGR of 4% in China.

Figure 19 – Exportable surplus from top five importing countries

Countries Taiwan Korea China Japan Iran Total

Capacity (kt) 1,930 1,470 25,200 2,090 730 31,420

Domestic Demand (kt) 700 700 18,000 1,450 350 21,200

Production (kt) 1,814 1,400 18,900 1,881 657 24,652

Exportable quantity (kt) 1,114 700 900 431 307 3,452

Likely exports to India in 2015-16 (kt) 470 390 220 250 110 1,440

Further quantity exportable from top 5 in 2020 (kt) 644 310 680 181 197 2,012

Source: Industry reports


14

As seen in the above table, the further quantity that can be exported from the top five countries is 2

million tons. It would however be naïve to assume that these countries would export only to India and no

one else. There could also be growth in demand within these countries that can further depress

availability. The risk of Chinese capacity coming down is very real. The PVC manufacturing industry in

China is currently facing technological challenges. Currently, only 20% of its manufacturing process is

based on the ethylene route while the remaining 80% is based on the acetylene route, which is the coal

based calcium carbide process. This process has come under pressure on account of air pollution, mercury

pollution, international conventions on Mercury and depletion of Mercury resources in China. The

Minamata Convention on Mercury requires reduced usage of Mercury in VCM manufacturing, in terms of

per unit production by 50% by 2020 compared to levels in 2010. The Chinese Government has already

issued a directive asking manufacturers to switch to low mercury catalysts. This involves considerable

capital expenditure and considering that the Chinese manufacturing capacity is fragmented with many

players having capacities lower than 100kt, it remains to be seen how many can economically take on this

kind of a capital expense. This would bring into doubt not only the exportable surplus of PVC that would

be available in China but also the ability of the local manufacturers to meet domestic demand, thereby

providing manufacturers based in Taiwan and Korea a market closer than India to offload their surplus.

All these point to clear possibilities of international suppliers not being able to meet the demand in India

in the future, thereby making capacity addition in the domestic industry an absolute must.

Caustic soda finds applications in a wide variety of sectors including Textiles, Alumina, Pulp & Paper and

others. The application mix varies slightly when compared to global consumption patterns as the use of

Caustic soda in textiles is relatively more prevalent in India. With respect to chlorine, there is a marked

variation when compared to the global scenario. Globally, 40% of the chlorine produced is used by the

vinyl industry whereas only 7.8% of the chlorine produced in India is used. This is due to lack of

expansion in PVC production capacity in India. As a consequence, the chlor-alkali industry in India is a

caustic driven industry unlike the rest of the world, where it is a chlorine driven industry. The sectoral

consumption of Caustic Soda & Chlorine, both at the global and country level, is given below:

Caustic Soda domestic capacity additions being hindered by lack of PVC capacity growth


15

Figure 20: Indian Caustic Soda Segment Breakup (%)

Source: AMAI

Vinyls 8%

Inorganics 12%

HCl 14%

Water Treatments 3%

Others 63%

Figure 21: Global Caustic Soda Segment Breakup (%)

Organics 17%

Alumina 17%Others 20%

Water Treatment 3%

Soaps & Detergents 7%

Textiles 10%

Inorganics 10%Pulp and Paper 16%

Source: AMAI

Figure 23: Global Chlorine Segment Breakup (%)

Vinyls 40%

Inorganics 22%

HCl 12%

Water Treatment 6%

Others 20%

The domestic demand for Caustic soda was at 3,231 kt in 2014-15. Total domestic production stood at

2,761kt while imports were at 508kt. Imports has been increasing over the past few years at a rate faster

than capacity addition (ref to figure 24).


16

Alumina 13%

Organics 10%

Pulp and Paper 10%

Inorganics 7%

Textiles 21%

Soaps & Detergent 7%

Water Treatment 2%

Others 30%

Figure 22: Indian Chlorine Segment Breakup (%)

Source: AMAI

Indian caustic demand, in addition to its steady growth as a basic alkali that goes into very many sectors,

will also be greatly driven by the expanding alumina capacity along the East Coast. Several projects have

been announced and are at various stages of implementation. The impact of these on caustic soda

demand is tabulated below.

Figure 24 - Caustic Soda supply - demand

-10%

0%

10%

20%

30%

40%

50%

60%

70%

0

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2010-11 2011-12 2012-13 2013-14 2014-15

Production (kt) Domestic demand (kt)

Capacity growth rate (%) Import growth rate (%)

Qua

nti

ty(k

t)

Source: AMAI

Current Proposed Total Current After

expansions

mtpa mtpa mtpa ktpa ktpa

Lanjigarh - Orisa 1.40 3.60 5.00 168 600 Damanjodi - Orisa 2.10 - 2.10 252 252

Belgaum - Karnataka 0.35 0.35 42 42

Muri - Jharkand 0.45 0.45 54 54

Renukut - UP 0.70 0.70 84 84

Utkal Alumina Project Rayagada - Orisa 1.50 - 1.50 135 135

Aditya Alumina & Aluminium Project

Kanariguda - Orisa 1.50

1.50

180

Anrak Aluminium Makavarapalem - AP 1.50 1.50 180

Jindal Aluminium Vizianagaram - AP 1.40

1.40

168 Total 6.50 8.00 14.50 735 1,695

Nalco

Hindalco

Refinery Capacity Refinery Lye Demand

Vedanta

Alumina Producers Location

Figure 25 : Alumina producer's overview in India (KTPA)

There is thus enormous scope for adding to the caustic soda capacity in the country, if only a fix can be

found for sinking the additional chlorine volume. And there is no better solution to this than expanding

the vinyls capacity.


17

What ails PVC and Caustic capacity addition? 04

From the foregoing, it is very evident that there is enormous gap between supply and demand in both PVC

and caustic industry, which would only increase at a rapid pace as we go forward. This then begs the

question – why capacity creation is not taking place, even to the extent of part of the demand growth?

Caustic soda imports have increased over the last five years at a CAGR of 22% while demand has grown at

a CAGR of 4.6%. Capacity and production have grown only at 0.8% and 2.4% CAGR respectively. The

increased arrival of imports has resulted in lower average capacity utilization of 80% in the domestic

caustic soda industry (ref to figure 26).

Imports (kt) Import growth rate (%)

Source: AMAI, EXIM

0%

10%

20%

30%

40%

50%

60%

70%

0

100

200

300

400

500

600

700

2010-11 2011-12 2012-13 2013-14 2014-15

Qua

nti

ty (

kt)

Impo

rt g

row

th (

%)

Figure 26 - Imports of Caustic Soda (2010-2015)


18

Caustic soda capacity growth has also been stunted due to the lack of addition of vinyl capacity as well as

derivatives industry for off- take of chlorine. Chlor-alkali industry is a power and water intensive

industry. Huge imports are arriving into India from countries in the Middle East where power is cheap.

Inadequate trade control measures are resulting in unregulated imports leading to low capacity

utilizations in the domestic vinyl industry. Also, capacity addition has stagnated and has not kept up

with demand. This can be attributed to the lack of availability of merchant ethylene and higher input

costs due to non-availability of adequate feedstock (EDC & VCM) in India (except for chlorine from the

caustic soda industry). The delay in PCPIR – Petroleum, Chemicals & Petrochemical Investment Regions

has resulted in non availability of merchant ethylene for stand alone downstream use. The low duty on

PVC and low duty differential is leading to inadequate margins in the end market.

Lack of institutional support in growth segments like crop protection chemicals, water treatment, etc.

are stymieing growth in chlorine consumption while growth in alumina capacity triggers growth in

caustic soda capacity. For caustic capacity to grow, the chlorine that is generated would need to be

consumed and for this vinyl capacity addition is a must

When we look at PVC, it is apparent that India has been attractive to capacities worldwide. For instance,

import data over the last six months shows that India has imported material from over 24 countries,

which include Korea, Taiwan, Japan, China, and EU countries along with U.S.A, U.K. as well as Brazil and

Colombia. Due to the low import duty for PVC in India and the availability of a fast growing market,

international suppliers are able to offload their surplus material easily in India. The import duty is lower

than most developed and developing countries (ref to figure 27).

7.50%10%

14% 15%

20%

India Indonesia Brazil Philippines Malaysia

Figure 27: Import duty in other countries

Source: CPMA

Moreover the lower duty differential between PVC and imported feedstock compared to that in other

countries that similarly depend on imported feedstock further discourages local capacity creation (ref to

figure 28).


19

Figure 28 - Duty Differential comparison

Product Countries dependent on imported feedstock

EDC 2 0 3

VCM 2 0 0

PVC 7.5 20 15

Duty Differential

PVC - EDC 5.5 20 12

PVC - VCM 5.5 20 15

India Malaysia Philippines

In fact, MNCs are not interested in creating capacities in India, despite this sector being open to FDIs

from 90s onwards, but do so outside India, which is also borne out by the proportion of exports in 2014

by Korea & Taiwan (the top two exporting countries to India) to India in relation to their total exports.

575

500

600

700

800

400

300

200

100

0

52%

751

43%

Korea Taiwan

Total exports Exports to India

Figure 29 – PVC – Importance of Indian market for Korea & Taiwan (kT)

Thus, while their supply levels easily support an establishment of a global scale plant in India, they do

not find it attractive to invest.

The Government has imposed ADD on imports from certain countries. However, ADD is not enough to curb

imports as this only addresses part of the gap between fair price and unfair price at which dumping takes

place, and, imports still arrive into the country using tariff concessions available through FTA, including

misuse of anomalies in the tariff classification, as well as from countries where ADD is not applicable.

Moreover, the relatively high interest rate environment and the poor development of infrastructure in the

country increase transaction costs for businesses which further serves as an impediment to growth in the

vinyls industry.


20

Free Trade Agreements - Relevance

Over the last few years, India has entered into a number of Trade Agreements (TAs) including free trade

agreements, preferential trade agreements, comprehensive economic cooperation agreements and

comprehensive economic partnership agreements in order to increase its foreign trade, particularly

exports. Some of the agreements signed by India are Comprehensive Economic Cooperation Agreement

(Singapore), Comprehensive Economic Partnership Agreement (South Korea & Japan), India – Malaysia

Free Trade Agreement, India – ASEAN Free Trade Agreement, etc.

India has committed to reducing import duties on imports of PVC, EDC or VCM in almost all the TAs, but

timing and extent of reduction varies. There is a risk of inversion of import duties across the PVC value

chain as a result of the trade patterns between India and the TA as well as non-TA countries. Today, the

PVC industry imports most of its feedstock from countries with which India does not have TA. As a result

of the TAs, India will have lower or no import duty for some TA countries on PVC but will continue to have

to import EDC and VCM from non-TA countries at the current import duty of 2%. This would further narrow

the duty differential, if not turning them in to negative, which has already impacted capacity addition in

the industry. As an illustration, in the case of Japan, duty on PVC will be reduced to zero by the end of

2019. This has helped imports of PVC from Japan jump from an average of 3kt per month in FY15 to an

average of 18kt per month in FY16. This number is expected to further increase. Granted, by 2019, duty

on imports of EDC and VCM from ASEAN member countries, South Korea and Japan will also be removed.

However, India imports only a minor share of its requirements of these products from this set of

countries, and as such, this is not likely to benefit local PVC industry in any great way. Indonesia is the

only TA country that supplies EDC and Japan is the only significant supplier of VCM, with which India has

a TA. India actually imports most of its EDC & VCM from Arab countries, the USA & Europe with which it

does not have any TAs. It is also thus critical that India does not agree for any duty concession on any PVC

product in its negotiations on RCEP and keeps all three HS codes – 390410, 390421 & 390422 – under

“exempt” category.


21


22

Recommendations for augmenting PVC & Caustic Soda Capacities

05

Given below are some suggested measures, both fiscal and policy, that can go a long way in enthusing investments in capacity augmentation, both by Indian companies as well as MNCs.

• Increase import duty of PVC & caustic soda from 7.5% to 10%. This will help revive the investment sentiment for the PVC industry in India. It will lead to increase in domestic PVC manufacturing in India and reduce imports thereby saving foreign exchange. Another impact would be local value addition and increase in jobs locally. Moreover, there would be minimal impact on prices i.e. downstream industry would be unaffected

• Reduce tariff on intermediates (EDC & VCM) to zero. As there is no local manufacture of EDC or VCM for merchant sale, any duty reduction will not adversely affect any domestic company. Facilities that are used to manufacture these intermediates are usually set up only for captive use. This proposal will therefore also not impact setting up of such facilities

• Revisit tariff concessions extended to countries with which India has signed Trade Agreements, especially the ones that export into India

• Give thrust to the PCPIR policy, ensuring availability of ethylene for downstream units. Developed petrochemical infrastructure can greatly reduce logistics cost. E.g., in countries with developed petrochemical infrastructure, intermediary feedstock is sourced off a pipeline. In India, these products are shipped across long distances involving huge logistics cost which makes domestic manufacturers uncompetitive compared to international counterparts

All these measures can result in a potential investment of over Rs. 20,000 crores over the next 5-7 years, in addition to possible investments in the upstream and downstream sectors.

6. ConclusionsBoth the PVC and the caustic soda industries are essential to the growth of the Indian economy with both

products finding applications in a variety of sectors as well as being a source of employment. Today,

close to 50% of the demand for PVC in the country is met by imports. Though the level of imports have

been increasing over the years and thereby meeting the supply-demand deficit for PVC in the country, it

remains to be seen whether this can be sustained over the medium to long term when domestic demand

grows. Very little capacity expansion is seen in the countries which are currently exporting to India,

meaning that there is an upper threshold beyond which these countries cannot supply. There could be a

case in the future where Indian demand for PVC could possibly outstrip supply. This would lead to

processed PVC products not being available for use as well as a lot of downstream processing facilities

having poor capacity utilization levels. The immediate effect would be loss of employment. Considering

that tens of thousands of people are employed by the PVC downstream industry, the effects would be

detrimental. It would also have a deleterious impact on the foreign exchange outflow and the trade

deficit. Increase in domestic production capacity of PVC would give processors a secure and stable source

of supply whereby plant capacity utilizations levels can be high leading to wealth creation in the

economy.

Increase in PVC production capacity will also facilitate increase in chlorine utilization leading to better

ECU economics and enhancement in caustic soda capacity. Caustic soda production capacity

enhancement is also reducing due to the influx of cheaper imports from the Middle East, where power

costs are lower. When the country's goal today is to 'Make in India', increased imports and lower

manufacturing levels contribute to loss of potential employment and widening the current account

deficit

As such, unless certain corrective fiscal measures are taken, India runs the risk of missing out on the

growth opportunities in both these sectors.


23

7. AbbreviationsADD – Anti Dumping Duty

AMAI – Alkali Manufacturer's Association of India

ASEAN – Association of South East Asian Nations

BRICS – Brazil, Russia, India, China and South Africa

CAGR – Cumulative Average Growth Rate

CPMA – Chemicals and Petrochemicals Manufacturer's Association

EDC – Ethylene Dichloride

FICCI – Federation of Indian Chambers of Commerce and Industry

FMCG – Fast Moving Consumer Goods

FTA – Free Trade Agreement

GDP – Gross Domestic Product

MNC – Multi National Company

PVC – Poly Vinyl Chloride

PCPIR – Petroleum, Chemicals and Petrochemicals Investment Region

RCEP - Regional Comprehensive Economic Partnership

TSMG - TATA Strategic Management Group

VCM – Vinyl Chloride Monomer


24

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25

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9. Tata Strategic Contacts

Karthikeyan.K.S

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Phone: +91 22 6637 6756

Report co-authored by Manish Ratna, Business Analyst ([email protected]), TSMG.


26

Established in 1927, FICCI is the largest and oldest apex business organisation in India. Its history

is closely interwoven with India's struggle for independence, its industrialization, and its

emergence as one of the most rapidly growing global economies.

A non-government, not-for-profit organisation, FICCI is the voice of India's business and industry.

From influencing policy to encouraging debate, engaging with policy makers and civil society,

FICCI articulates the views and concerns of industry. It serves its members from the Indian private

and public corporate sectors and multinational companies, drawing its strength from diverse

regional chambers of commerce and industry across states, reaching out to over 2,50,000

companies.

FICCI provides a platform for networking and consensus building within and across sectors and is

the first port of call for Indian industry, policy makers and the international business community.

ABOUT FICCI

Industry’s Voice for Policy Change

Mr. P. S. SinghHead-Chemicals &

Petrochemicals DivisionFICCI

Federation House, 1 Tansen MargNew Delhi-110001

Tel: +91-11-23316540 (Dir)Email: [email protected]

Ms. Rinky SharmaResearch Associate

Chemicals & PetrochemicalsFICCI

Federation House, 1 Tansen MargNew Delhi -110001

T: 011-23487473 (Ext: 473)Email:[email protected]

FICCI Contacts

Documents

FICCI : Industry's Voice for Policy Change - White Paper on ...ficci.in/spdocument/20684/PVC-Report.pdf10.3 kg per capita in China (ref to figure 3). The forecasts for the PVC industry